Secure adjustable orthotic device

ABSTRACT

A secure adjustable orthotic device having multiple brace portions and one or more locking mechanisms. One locking mechanism is a level moving buckle comprising a top member, a locking member and a base member. The locking member is adapted to engage and disengage an inserted strap in response to the longitudinal movement of the top member relative to the base member. The level moving buckle inhibits accidental longitudinal movement of the inserted strap when the top member is in a locked position.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to U.S. Provisional ApplicationNo. 61/438,509, entitled “Secure Adjustable Orthotic Device,” filed Feb.1, 2011, the entire contents of which are herein incorporated byreference.

FIELD OF THE INVENTION

The present invention generally relates to a secure adjustable orthoticdevice or orthosis (commonly known as a brace or splint) comprisingvarious buckles, straps, and adjustable supports. More particularly, theinvention relates to an orthotic device having level moving buckles andsecure adjustable supports.

BACKGROUND OF THE INVENTION

In certain orthosis applications, it is important that buckles andadjustable supports be easy to use while also inhibiting the accidentalrelease, tightening or adjustment of an inserted strap (in the case of abuckle) or bracket (in the case of an adjustable support). For example,a common method of alleviating pain, promoting healing, and preventingfurther injury in patients who have suffered a back or spine injury (orin post-operative spinal surgery patients) is to stabilize the spine bymeans of an orthotic device. Among other things, an orthosis can providestabilization, support, protection, pain reduction and replacement oflost function. Many orthotic devices rely on buckles, belts/straps,adjustable supports, and brackets to allow the donning or doffing of thedevice, and for adjusting and maintaining the device's fit/support.

There are a large variety of braces available depending on the diagnosisand physical needs of the individual. These devices include a multitudeof construction materials and buckling and support designs for fittingthe device around the patient's trunk or peripheral area, such as thecervical and pelvic regions.

Such braces are effective in achieving spinal stability if worn properlyand consistently. However, most patients have difficulty in manuallyadjusting the brace's belts or straps so that the brace fits tightlyenough to provide adequate support and stability but not so tight thatthe brace itself becomes a source of pain or discomfort, or causes thedisruption of circulation. This is especially true in the case ofpost-operative patients who are generally in pain, have a limited rangeof motion, and frequently lack sufficient strength to make necessaryadjustments to the brace by way of the brace's buckles and straps.

U.S. Pat. No. 4,406,043 discloses a belt buckle comprising a frame andpivotable tongue that engages the perforations in a flexible belt.Buckles of this general type can be difficult and uncomfortable tooperate, particularly for persons with limited strength or mobility,such as post-operative patients. To secure or release a belt or strapusing this type of buckle, the belt must be over-tightened before thepivotable tongue can be inserted into, or removed from, the desiredperforation. Further, because each perforation reduces the structuralintegrity of the belt, buckles of this type are limited to applicationsnot requiring fine adjustments to fit.

U.S. Pat. No. 4,688,337 discloses a two-piece clasp comprising a maleclasp piece having parallel resilient arms that inset and lock intocorresponding slots in a receptacle clasp piece. Straps are threadedthrough bars on the free ends of each clasp piece. A disadvantage ofbuckles of this general type is that manual adjustment of the strapsthrough the bars on the freed ends of each clap piece is difficult,particularly for post-operative patients having limited strength andrange of motion.

U.S. Pat. No. 4,903,381 teaches a fastener that accepts a strap in areceiving channel wherein a spring-loaded arresting member engages aserrated region of the strap thereby preventing the withdrawal of aninserted strap. A disadvantage of fasteners or buckles of this type isthat, during a patient's daily activities, it is possible for a force orpressure to be applied to the strap in the insertion direction, therebycausing the strap to be tightened unintentionally and causing pain,discomfort, or loss of circulation.

U.S. Pat. No. 376,055 discloses a buckle comprising a clasp wherein theclasp grips an inserted belt or strap. The strap or belt is released bypulling up on the free end of the clasp. A buckle having similarfeatures is taught in U.S. Pat. No. 5,572,771. A drawback to buckles ofthis type is that the strap or belt can be accidentally released if thefree end of the clasp is pulled open accidentally by the patient'sclothing or in some other way during the patient's daily activities.

Existing orthotic devices, such as described in U.S. Pat. No. 7,371,221,immobilize the head relative to the base using a single support bracketand a single locking pin located at the back of the cervical brace.However, such devices present the problems of being difficult for theuser to adjust without assistance, and accidental release of the lockingpin and the accompanying loss of support. As discussed above, it isimportant that adjustable supports be easy to use while also preventingaccidental release.

The present invention satisfies these and other needs, and providesfurther related advantages.

SUMMARY OF THE INVENTION

For purposes of summarizing the disclosure, exemplary embodiments of asecure adjustable orthotic device having one or more locking mechanismshave been described herein.

The present invention may be embodied in a locking mechanism for asecure adjustable orthotic device. In one embodiment, the lockingmechanism comprises a base member, a locking member and a top member.The base member comprises a base portion, a first side portion and asecond side portion that, together, form a longitudinal channel forreceiving a free end of a strap. The locking member is pivotallyattached to the base member and is pivotable between a locked positionand an unlocked position. The locking member comprises a firstprojection extending in a first direction and a second projectionconnected to the first projection but extending in a second direction.The first projection of the locking member has a first surface, a secondopposite surface and a third surface. The second projection has asurface that engages an inserted strap when the locking member is in thelocked position. The top member is slidably attached to the base memberand comprises a top portion and one or more protrusions extending towardthe locking member. Longitudinal movement of the top member relative tothe base member in a first locked direction causes the one or moreprotrusions of the top member to apply a force to the first and then thethird surfaces of the first projection of the locking member, pivotingthe locking member to the locked position. Assuming a strap has beeninserted into the longitudinal channel, the second projection of thelocking member engages the inserted strap, thereby impeding thelongitudinal movement of the strap. Longitudinal movement of the topmember in a second opposite direction relative to the base member causesthe one or more protrusions of the top member to apply a force to thesecond opposite surface of the first projection of the locking member,pivoting the locking member to the unlocked position and causing thesecond projection of the locking member to disengage the inserted strap,thereby allowing the longitudinal movement of the strap.

In another embodiment, at least one aperture is formed in the baseportion of the base member so that the locking mechanism can be attachedto other objects or surfaces. For example, the locking mechanisms can beattached to an orthotic device or orthosis (commonly known as a brace orsplint).

In a further embodiment, a first aperture is formed in the first sideportion of the base member, and a second aperture is formed in thesecond side portion of the base member. The locking member comprises afirst protrusion extending in a first direction and a second protrusionextending in a second opposite direction. The first protrusion of thelocking member is inserted into the first aperture in the first sideportion of the base member. The second protrusion of the locking memberis inserted into the second aperture in the second side portion of thebase member. The first and second protrusions of the locking member forma transverse axis along which the locking member is free to pivotbetween the unlocked and locked positions based on the longitudinalmovement of the top member relative to the base member.

In another embodiment, the first and second protrusions of the lockingmember are spindles. The first and second protrusions can be formed fromthe same material as that used to form the locking member.Alternatively, the first and second protrusions can be formed byinserting a support shaft or axle made of metal or other hard substancethrough the locking member.

In yet another embodiment, a first slot is formed in the outer surfaceof the first side portion of the base member and a second slot is formedin the outer surface of the second side portion of the base member. Thefirst and second slots are parallel to the plane of the base portion ofthe base member and are located near the top edges of the first andsecond side portions of the base member. Preferably, the first andsecond slots terminate prior to the longitudinal ends of the first andsecond side portions of the base member. In this embodiment, the topmember has a first lip extending from a first side edge of the topportion of the top member in a direction perpendicular to the plane ofthe top portion of the top member and a second lip extending from asecond side edge of the top portion of the top member in a directionperpendicular to the plane of the top portion of the top member. A firsttongue is formed on the interior surface of the first lip of the topmember and a second tongue is formed on the interior surface of thesecond lip of the top member. The first tongue formed on the interiorsurface of the first lip of the top member is inserted into the firstslot formed in the outer surface of the first side portion of the basemember and the second tongue formed on the interior surface of thesecond lip of the top member is inserted into the second slot formed inthe outer surface of the second side portion of the base member, therebyslidably attaching the top member to the base member. Alternatively,multiple short slots can be formed on the outer surfaces of the firstand second side portions of the base member and multiple correspondingtongues can be formed on the interior surfaces of the first and secondlips of the top member.

In another embodiment, first and second channels are formed on the innersurfaces of the first and second side portions of the base member. Thechannels run parallel to the plane of the base portion and are locatednear the top edges of the first and second side portions. Preferably,the channels terminate prior to the longitudinal ends of the first andsecond side portions of the base member. In this embodiment, a firstside edge of the top portion of the top member is inserted into thefirst channel formed on the inner surface of the first side portion ofthe base member, and a second side edge portion of the top portion ofthe top member is inserted into the second channel formed on the innersurface of the second side portion of the base member, thereby slidablyattaching the top member to the base member.

In a further embodiment of the locking mechanism, the locking member isjuxtaposed to the base member. In this embodiment, a majority of thelocking member is located within a well formed in the top surface of thebase portion of the base member so that, in the unlocked position, thelocking member does not obstruct the longitudinal channel formed by thebase member. Alternatively, a majority of the locking member is proximalto the top member so that, when a strap is inserted into the lockingmechanism's longitudinal channel, a majority of the locking member islocated between the top member and the inserted strap.

The present invention may additionally be embodied in a lockingmechanism that inhibits the locking member from pivoting from a lockedposition to an unlocked position when tension is applied to the strapinserted into the longitudinal channel of the locking mechanism. Thisembodiment comprises a top member having a protrusion extending awayfrom the plane of the top member and toward the locking member. Theprotrusion has a first angled surface relative to the plane of the topmember and a second parallel surface relative to the plane of the topmember. Longitudinal movement of the top member in a first lockingdirection causes initial contact between the first angled surface of theprotrusion of the top member and the first surface of the firstprojection of the locking member. This initial contact with the firstangled surface of the protrusion of the top member applies a force tothe first projection of the locking member, the force having a downwardvector component relative to the plane of the top member. The downwardforce causes the first projection of the locking member to move in adirection perpendicular to the plane of the longitudinal channel andtoward the base member so that the locking member pivots to the lockedposition, causing the second projection of the locking member to engagea strap inserted into the longitudinal channel and thereby preventingthe withdrawal of strap. Further lateral movement of the top membercauses the second surface of the protrusion of the top member that isparallel to the longitudinal movement of the top member to align with athird surface of the first projection. The third surface is parallel tothe second surface of the protrusion of the top member. Thus, when thetop member is in the fully locked position, contact between theprotrusion of the top member and the third surface of the firstprojection of the locking member is along a plane parallel to thelongitudinal movement of the top member. If tension is applied to thestrap when the top member is in the locked position, the strap willapply a force to the second projection of the locking member in thedirection of the base member. This force will be communicated throughthe rigid structure of the locking member and its transverse pivot,causing the third surface of the first projection of the locking memberto apply a force to the second surface of the protrusion of the topmember in a direction away from the base member. Because the planes ofthe third surface of the first projection of the locking member and thesecond surface of the protrusion of the top member are substantiallyparallel to the longitudinal movement of the top member (and the forceis in a direction substantially perpendicular to the longitudinalmovement of the top member), the top member does not move longitudinallyin the unlocking direction and thus prevents the withdrawal of thestrap.

In another embodiment, the strap that can be inserted into the lockingmember's longitudinal channel has a series of transverse teeth on onesurface. In this embodiment, the second projection of the locking memberforms a pawl that is shaped to engage the transverse teeth of aninserted strap.

The present invention may also be embodied in an adjustable orthoticdevice comprising a first brace portion, a second brace portion, a thirdbrace portion, a bracket portion, and an adjustment tool. The bracketportion interconnects the first brace portion and second brace portion,and is fixedly attached to the first brace portion and slidably attachedto the second brace portion. The bracket portion comprises first andsecond parallel projections, each projection having a plurality ofapertures longitudinally spaced along a portion of its length. Thesecond brace portion comprises a body portion and a pair of lockingmembers attached to the body portion and spaced apart from one another.The first and second locking members of the second brace portion eachhas a top portion having an aperture, a first side portion and a secondside portion together forming a longitudinal channel adapted to receivethe first and second projections of the bracket portion respectively.Each locking member also has a pin having a diameter smaller than theaperture in the top portion of the locking member. The pin has a firstend sized to fit within each of the apertures of the projections of thebracket portion (the pin being slidable in a first locked direction anda second unlocked direction along an axis defined by the longitudinalaxis of the pin's shaft. The pin further has a first projectionproximate to the first end of the pin and defining an axis substantiallyperpendicular to the longitudinal axis of the pin, a second opposite endhaving a second projection defining an axis substantially parallel tothe first projection, and a spring that applies a force to the firstprojection of the pin in the locked direction. The third brace portionis detachably coupled to the first and second brace portions. Theadjustment tool comprises a body portion, a first end portion, and asecond end portion. The first and second end portions are spaced apartfrom one another. The first and second end portions each has a slotdefining an axis and a first pair of surfaces adjacent to the slot,wherein surface is tapered in a direction parallel to the axis of theslot. The slots of the first and second end portions of the adjustmenttool are oriented to accept the second ends of the pins of the lockingmembers. As the first and second end portions of the adjustment tool arepushed toward the second ends of the pins, the tapered surfaces adjacentto each slot of the adjustment tool apply a force to the lips of thepins. This force is greater than the force applied by the springs,thereby causing the pins to move in the second unlocked direction. Whenthe first and second ends of the adjustment tool are fully insertedunder the lips of the two pins of the locking members, the first ends ofthe pins withdraw from the apertures of the first and second projectionsof the bracket portion, allowing the bracket portion (and the firstbrace portion fixedly attached thereto) to be adjusted relative to thesecond brace portion.

The present invention is additionally embodied in a locking mechanismwherein the first brace portion is a mandibular support, the secondbrace portion is a front sternum plate, and the third brace portion is aoccipital-scapular plate.

These and other features and advantages of the present invention will bemore readily apparent from the detailed description of the embodimentsset forth below taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described, by way ofexample only, with reference to the following drawings.

FIG. 1A is perspective view of a locking mechanism, in accordance withan embodiment of the present invention.

FIG. 1B is an exploded view of the locking mechanism shown in FIG. 1A.

FIG. 2 is an enlarged perspective view of a base member, in accordancewith an embodiment of the present invention.

FIG. 3 is an enlarged perspective view of a locking member, inaccordance with an embodiment of the present invention.

FIGS. 4A and 4B are enlarged top and bottom perspective views of a topmember, in accordance with an embodiment of the present invention.

FIGS. 5A through 5C inclusive are perspective views that show,respectively, (i) a strap prior to insertion into one of the lockingmechanisms shown in FIG. 1, (ii) the strap inserted into the lockingmechanism, wherein the locking mechanism is in the unlocked position,and (iii) the strap inserted into the locking mechanism, wherein thelocking mechanism is in the locked position.

FIGS. 6A and 6B are cross-sectional views of the locking mechanisms ofFIGS. 5B and 5C, respectively.

FIG. 7 is a perspective view of an orthotic device having secureadjustable supports, in accordance with an embodiment of the presentinvention.

FIG. 8 is a perspective view of a portion of the secure adjustableorthotic device and an adjustment tool, in accordance with an embodimentof the present invention.

FIG. 9 is an exploded view a locking member removed from a lockingmechanism housing of a second brace portion of the secure adjustableorthotic device shown in FIG. 8.

FIGS. 10A-10C are side views of an assembled locking member shown inFIG. 9, along with an adjustment tool and a bracket portion of thesecure adjustable orthotic device, in accordance with an embodiment ofthe present invention.

Exemplary embodiments and their advantages are best understood byreferring to the detailed descriptions that follow. It should beappreciated that like reference numerals are used to identify likeelements illustrated in one or more of the figures, wherein showingstherein are for purposes of illustrating exemplary embodiments and notfor purposes of limiting the same.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in detail, FIGS. 1A and 1B FIG. 1 show arepresentative locking mechanism 1 according to the present inventioncomprising a base member 2, a locking member 12, and a top member 3.

Referring to FIGS. 1A and 2, the base member 2 is formed by a baseportion 4, a first side portion 5 and a second side portion 6 that forma longitudinal channel 7 for receiving a free end of a strap 31 (shownin FIGS. 2A through 2C). In this embodiment of the base member, at leastone aperture 8 is formed in the base portion of the base member to allowthe locking mechanism to be attached to other objects, such as anorthotic device. A first aperture 9 is formed in the first side portion5 of the base member, and a second aperture 8 is formed in the secondside portion 6 of the base member. A well 11 is formed in the topsurface of the base portion of the base member to accommodate thelocking member 12. A plurality of slots 10 are formed in the outersurfaces of the first and second side portions of the base member. Theslots are parallel to the plane of the base portion 4 of the base memberand terminate prior to the longitudinal ends of the first and secondside portions of the base member.

As shown in FIGS. 1B and 3, the locking member 12 comprises a pluralityof first projections 15 a, 15 b, and 15 c extending in a first directionand a second projection 16 connected to the plurality of firstprojections but extending in a second direction. The first projection 15a of the locking member has a first surface 17 and a third surface 19.The first projections 15 b and 15 c have second opposite surfaces 18.The second projection 16 has a surface 20 capable of engaging aninserted strap 31 (shown in FIGS. 2A through 2C) when the locking member12 is pivoted to, or is in, the locked position. A first finger 13 a ofthe locking member shown in FIG. 3 extends in a first direction and asecond finger 13 b extends in a second opposite direction. The first andsecond protrusions of the locking member form a transverse rotationalaxis.

In order to pivotally attach the locking member 12 to the base member 2,the first finger 13 a of the locking member is inserted into the firstaperture 9 a in the first side portion 5 of the base member, and thesecond finger 13 b of the locking member is inserted into the secondaperture 9 b in the first side portion 5 of the base member. The firstand second protrusions of the locking member form a transverse axisalong which the locking member is free to pivot between an unlocked anda locked position.

FIGS. 4A and 4B show a top member 3 having a top portion 25, a first lip21 extending from a first side edge 26 a of the top portion of the topmember in a direction perpendicular to the plane of the top member and asecond lip 22 extending from a second side edge 26 b of the top portionof the top member in a direction perpendicular to the plane of the topmember. A plurality of first tongues 23 are formed on the interiorsurface of the first lip 21 of the top member, and a plurality of secondtongues 24 are formed on the interior surface of the second lip 22 ofthe top member.

FIG. 4B shows the bottom surface of top member 3. A first protrusion 27a and a second protrusion 27 b are formed on the inner surface of thetop portion of the top member. The first protrusion 27 a has an angledfirst surface 28 (relative to the plane of the longitudinal movement ofthe top member), a second surface 29 that is parallel to the plane ofthe longitudinal movement of the top member, and a third surface 30. Thefirst and second protrusions each also has a strap alignment surface 37.

According to the embodiment shown in FIG. 1, in order to slidably attachthe top member 3 to the base member 2, the first tongues 23 formed onthe interior surface of the first lip 21 of the top member are insertedinto the plurality of first slots 10 a formed in the outer surface ofthe first side portion 5 of the base member. The second tongues 24formed on the interior surface of the second lip 22 of the top memberare inserted into the plurality of second slots 10 b formed in the outersurface of the second side portion 6 of the base member.

In another embodiment, first and second channels are formed on the innersurfaces of the first and second side portions of the base member. Thechannels run parallel to the plane of the base portion and are locatednear the top edges of the first and second side portions. Preferably,the channels terminate prior to the longitudinal ends of the first andsecond side portions of the base member. In this embodiment, a firstside edge of the top portion of the top member is inserted into thefirst channel formed on the inner surface of the first side portion ofthe base member, and a second side edge portion of the top portion ofthe top member is inserted into the second channel formed on the innersurface of the second side portion of the base member, thereby slidablyattaching the top member to the base member.

FIGS. 5A through 6B show an assembled embodiment of the lockingmechanisms 1 as it relates to a strap 31. FIGS. 5A and 5B show the strap31 prior to, and following, insertion into the longitudinal channel 7,wherein the top member 3 is in the unlocked position. The strap 31 isgenerally planar in shape, having first 34 and second 35 opposed majorsurfaces. The first major surface 34 of the strap 31 includes a seriesof longitudinally spaced transverse locking teeth 32(see FIGS. 6A-6B).FIG. 5C shows the strap inserted into the longitudinal channel 7 and thetop member 3 in the locked position.

FIG. 6A shows a longitudinal cross-sectional view of the embodiment ofthe locking mechanism shown in FIG. 5B. Specifically, longitudinalmovement of the top member 3 relative to the base member 2 in the“unlocked” direction 38 causes the third surface 30 of the firstprotrusion 27 a of the top member to apply a force to the secondopposite surfaces 18 of the first projections 15 b and 15 c of thelocking member 12. The force applied to surfaces 18 causes the lockingmember to pivot about its transverse axis, defined by fingers 13 a and13 b, to the unlocked position, wherein the second projection 16 pivotsinto the well 11 in the bottom portion 4 of the base member 2 so thatthe second projection 16 does not inhibit the insertion or adjustment ofthe strap 31 in the longitudinal channel 7.

As shown in FIG. 6B, which is a longitudinal cross-sectional view of theembodiment of the locking mechanism and strap shown in FIG. 5C,longitudinal movement of the top member 3 relative to the base member 2in the “locked” direction 36 causes the first protrusion 27 a of the topmember to apply a force to the first surface 17 of the first projection15 a of the locking member, pivoting the locking member to the lockedposition. In the locked position, the pawl 20 of the second projection16 of the locking member engages the inserted strap 31 and the strapalignment surfaces 37 of the first and second protrusions of the topmember 3 prevent the strap from deflecting away from the pawl 20 therebyimpeding the withdrawal of the strap. Specifically, longitudinalmovement of the top member in the locked direction 36 causes initialcontact between the angled first surface 28 of the first protrusion 27 aand the first surface 17 of the first projection 15 a of the lockingmember 12. Continued movement of the top member in the locked direction36 causes the first surface 28 of the protrusion to apply a force to thefirst projection 15 a of the locking member. Due to the angle of thefirst surface 28, the force applied to the first projection 15 a has adownward vector component (toward the base member). The applied forcecauses the locking member to pivot to the locked position, causing thesecond projection 16 of the locking member to engage a strap 31 insertedinto the longitudinal channel 7, thereby preventing the withdrawal ofstrap. In the embodiment of the locking mechanism shown in FIG. 6B, thesecond projection 16 of the locking member 12 forms a pawl having a freeend 20 shaped to fit the longitudinal spaces 33 between the transverselocking teeth 32 on the first surface 35 of the strap 31. When thelocking member pivots from the unlocked to the locked position followingthe insertion of a strap, the free end enters the longitudinal spacebetween adjacent transverse locking teeth, thereby obstructing thewithdrawal of the strap.

FIG. 6B also illustrates that the present invention may be additionallyembodied in a locking mechanism that inhibits the accidental movement orrelease of the strap 31 when the top member 12 is in the fully lockedposition because the application of a longitudinal force to the strap ineither direction will not cause the top member to move in the unlockeddirection 35. Specifically, when the top member in the fully lockedposition, the second surface 29 of the first protrusion 27 a aligns withthe third surface 19 of the first projection 15 a of the locking member.The aligned surfaces 29 and 19 are parallel to one another and parallelto the plane of the longitudinal movement of the top member 12.Therefore, attempting to withdraw or insert the strap 31 while thelocking mechanism is in the fully locked position creates a force thatdoes not result in movement at surfaces 29 and 19 because the generatedforce is in a direction perpendicular to the longitudinal movement inwhich the top member is free to engage.

FIG. 7 shows an orthotic device 36 having secure adjustable supportsaccording to the present invention. The orthotic device comprises afirst brace portion 38 forming a mandibular support, a second braceportion 40 forming a front sternum plate, and a bracket portion 42fixedly attached to the first brace portion and slidably attached to thesecond brace portion. The first brace portion 38 and second braceportion 40 each comprises a cushioned pad 39 and 41 respectively. Thesecond brace portion 40 further comprises a body portion 44, and a pairof locking members 46 spaced apart from one another. The bracket portion42 comprises a first projection 48 defining an axis and a secondprojection 52 spaced apart from the first projection and defining anaxis that is parallel to the axis defined by the first bracket 42. Thefirst projection 48 and second projection 52 of the bracket portion 42each has a plurality of apertures 50 longitudinally spaced along aportion of their length.

FIG. 8 is a perspective view of a portion of the second brace portion40, the first and second projections of the bracket portion 42, and anadjustment tool 84. The second brace portion includes the pair oflocking members 46. Each locking member comprises a housing 53 and alocking portion 55. The housing 53 of each locking member comprises atop portion 54 having an aperture 56, a first side portion 58 having afirst end 60 attached to the body portion 44 of the second brace portionand a second opposite end 62 attached to the top portion 54 of thelocking member, and a second side portion 64 having a first end 66attached to the body portion 44 of the second brace portion and a secondopposite end 68 attached to the top portion 54 of the locking member.The top portion 54, first side portion 58, and second side portion 64 ofeach locking portion housing 53 form a longitudinal channel 70configured to receive one of the first projection 48 or secondprojection 52 of the bracket portion 42.

The adjustment tool 84 comprises a body portion 86 having a first endportion 88 and a second end portion 90 that is spaced apart from thefirst end portion. The first and second end portions of the adjustmenttool 84 each has a slot 92 defining an axis 94, and a pair of surfaces96 adjacent to the slot. The surfaces 96 are tapered in a directionparallel to the axis 94. And because the first projection 50 and secondprojection 52 of the bracket 42 secure the first brace portion 38 to thesecond brace portion 40 at two independent locking members 46,adjustment requires the use of the adjustment tool 84, thereby reducingthe chance of accidental movement of the first brace portion relative tothe second brace portion.

FIG. 9 is an exploded view of a locking portion 55 extracted from thehousing 53 of a locking member 46 of the second brace portion 40 shownin FIGS. 7 and 8. Each locking portion 55 comprises a pin 72, a coiledspring 74, an annular disc 76, a cap 78, and a body portion 79. The pin72 comprises a first end 80, a second opposite end 82, and an annularlip 83 wherein the annular lip has an outer diameter larger than theinner diameter of the coiled spring 74. The first end 80 of the pin issized to fit within the apertures 50 of the projections 48 and 52 of thebracket portion 42. The cap 78 has an aperture 77 formed in the centerof its top and the body portion 79 has an aperture 81 formed in thecenter of its base. The second end 82 of the pin 72 has a diametersmaller than the diameter of the aperture 77 formed in the center of thetop of the cap 78.

When assembled, the second end 82 of the pin 72 is positioned within thecoiled spring 74 with the coiled spring abutting the annular lip 83 ofpin 72. The second end of the pin is inserted through the aperture 77 inthe top of the cap 78 and the annular disc 76 is coupled to the secondend 82 of the pin 72. The body portion 79 is then fixedly attached tothe cap 78. The first end 80 of the pin 72 is allowed to project throughthe aperture 81 in the center of the base of the body portion 79.thereby enclosing the coiled spring and majority of the pin 72. Thesecond end 82 of the pin 72 is positioned within the fixedly attachedwithin the aperture of the second annular disc 78 so that the secondannular disc is positioned between the first end 80 and the second end82 of the pin. The pin 72 of each locking portion is positioned throughthe aperture 56 formed in the top portion 54 of the housing 53. The pinis slidable between a first locked position and a second unlockedposition along a longitudinal axis defined by the shaft of the pin 72and substantially perpendicular to the plane of the top portion 54 ofthe housing 53 of the locking member 46. When the locking portion 55 iscontained within the housing 53 of the locking member 46, and the pin 72is in the locked position, its first end 80 extends into thelongitudinal channel 70 of the housing 53. When the pin 72 is in theunlocked position, its first end 80 is retracted from the longitudinalchannel 70 of the housing. The coiled spring 74 resists compressionbetween the annular lip 83 of the pin 72 and the cap 78 thereby applyinga force to the pin 72 in the locked position.

FIGS. 10A-10C are side views of an assembled locking portion 55extracted from the housing 53 of a locking member 46 of the second braceportion 40 shown in FIGS. 7-8. FIG. 10A shows the locking portion 55with the annular disc 76 and pin 72 in the locked position with a secondend portion 90 of the adjustment tool 84 approaching the locking portionfrom the left of the figure (it should be apparent that all depictionsof the second end portion 90 of the adjustment tool 84 are equallyrepresentative of the first end portion 88 of the adjustment tool). Alsoshown in FIG. 10A is a longitudinal cross section of the secondprojection 52 of the bracket portion 42 to illustrate the plurality ofapertures 50 longitudinally spaced along a portion of the secondprojection's length (it should be apparent that all depictions of thesecond projection 52 of the bracket portion 42 are equallyrepresentative of the first projection 48 of the bracket portion).

FIG. 10B shows the annular disc 76 and pin 72 of the locking portion 55in the unlocked position. Due to the angle of the tapered surface 96 ofthe second end portion 90 of the adjustment tool 84, insertion of theadjustment tool between the annular disc 76 and the cap 78 exerts aforce on the bottom of the annular disc 76 that has an upward component.When the upward component of the force applied to the annular disc 76(and the pin 72 to which the annular disc is coupled) by the insertionof the adjustment tool 84 overcomes the opposite force that the coiledspring 74 applies to the annular lip 83 of the pin 72 (and the annulardisc 76 to which it is coupled) due to the coiled spring's resistance tocompression, the annular disc 76 and pin 72 slide to the unlockedposition. As shown in FIG. 10B, when the annular disc 76 and pin 72 arein the unlocked position, the first end 80 of the pin retracts. When thelocking portion 55 is contained within the housing 53 of the lockingmember 46 and the pin 72 is in the unlocked position, the first end 80of the pin 72 is retracted from the longitudinal channel 70 of thehousing 53. With the first end 80 of the pin 72 retracted from thelongitudinal channel 70, the second projection 52 of the bracket portion42 can be inserted into, or adjusted within, the longitudinal channel70.

FIG. 10C shows the second end portion 90 of the adjustment tool 84removed from between the annular disc 76 and the cap 78 of the lockingportion 55. With the adjustment tool removed, the force applied by thecompressed coiled spring 74 to the annular lip 83 of the pin 72 causesthe pin to return to the locked position. When the locking portion 55 iscontained within the housing 53 of the locking member 46, and the pin 72returns to the locked position, its first end 80 extends into thelongitudinal channel 70 of the housing 53. With the second projection 52of the bracket portion 42 positioned within the longitudinal channel,the first end 80 of the pin 72 can enter one of the plurality ofapertures 50 longitudinally spaced along a portion of the secondprojection 52 of the bracket portion 42 thereby preventing theaccidental movement of the bracket portion 42 (and the first braceportion 38 to which it is fixedly attached) relative to the second braceportion 40 as show in FIG. 7.

The present invention has been described above in terms of presentlypreferred embodiments so that an understanding of the present inventioncan be conveyed. However, there are other embodiments not specificallydescribed herein for which the present invention is applicable.Therefore, the present invention should not to be seen as limited to theforms shown, which are illustrative rather than restrictive.

1. A locking mechanism comprising: a base member having a longitudinalchannel for receiving a free end of a strap, the base member comprisinga base portion, a first side portion connected to the base portion, anda second side portion connected to the base portion, wherein the baseportion, first side portion and second side portion form thelongitudinal channel; a locking member pivotally attached to the basemember and pivotable between a locked position and an unlocked position,wherein the locking member comprises a first projection extending in afirst direction, and having a first surface and a second oppositesurface, and a second projection connected to the first projection andextending in a second direction, wherein the second projection has afirst surface configured to engage the free end of the strap when thelocking member is in the locked position; and a top member slidablyattached to the base member, the top member comprising: a top portion,and one or more protrusions formed in the top portion and extendingtoward the locking member; wherein longitudinal movement of the topmember relative to the base member in a first direction causes the oneor more protrusions of the top member to apply a force to the firstsurface of the first projection of the locking member, pivoting thelocking member to the locked position; wherein, in the locked position,the first surface of the second projection of the locking member isconfigured to engage the free end of the strap, thereby impeding thewithdrawal of the strap; wherein longitudinal movement of the top memberin a second opposite direction relative to the base member causes theone or more protrusions of the top member to apply a force to the secondopposite surface of the first projection of the locking member, pivotingthe locking member to the unlocked position; and wherein, in theunlocked position, the first surface of the second projection of thelocking member is configured to disengage the free end of the strap,thereby allowing the withdrawal of the strap.
 2. The locking mechanismaccording to claim 1, wherein an aperture is formed in the base portionof the base member for fixedly coupling the locking mechanism to anorthotic device.
 3. The locking mechanism according to claim 1, wherein:the locking member comprises a first protrusion extending in a firstdirection and a second protrusion extending in a second opposite direct;the first protrusion of the locking member is inserted into a firstaperture in the first side portion of the base member; and the secondprotrusion of the locking member is inserted into a second aperture inthe second side portion of the base member.
 4. The locking mechanismaccording to claim 3, wherein the first and second protrusions of thelocking member are spindles formed from the same material as that usedto form the locking member.
 5. The locking mechanism according to claim3, wherein the first and second protrusions are formed by inserting anaxle transversely through the locking member.
 6. The locking mechanismaccording to claim 1, wherein: the base member further comprises a firstside portion including a first slot formed in the outer surface of thefirst side portion, and a second side portion including a second slotformed in the outer surface of the second side portion; the top memberfurther comprises a first lip extending from a first edge of the topportion of the top member, wherein a first tongue is formed on the innersurface of the first lip, and a second lip extending from a secondopposite edge of the top portion of the top member, wherein a secondtongue is formed on the inner surface of the second lip; and wherein thefirst and second tongues of the top member are inserted into the firstand second slots formed in the outer surfaces of the first and secondside portions of the base member, thereby slidably attaching the topmember to the base member.
 7. The locking mechanism according to claim6, wherein: the first and second slots formed in the outer surfaces ofthe first and second side portions of the base member are parallel tothe plane of the base portion of the base member, and are located nearthe top edges of the first and second side portions of the base member;and the first and second slots terminate prior to the longitudinal endsof the first and second side portions of the base member.
 8. The lockingmechanism according to claim 7, wherein a plurality of the slots areformed on the outer surface of each of the first and second sideportions of the base member.
 9. The locking mechanism according to claim7, wherein: a plurality of the tongues are formed on the inner surfacesof each of the first and second lips of the top member; and the locationof the plurality of tongues formed on the first and second lips of thetop member correspond to the plurality of slots on the first and secondside portions of the base member.
 10. The locking mechanism according toclaim 1, wherein: the base member further comprises a first side portionincluding a first channel formed in the inner surface of the first sideportion, and a second side portion including a second channel formed inthe inner surface of the second side portion; the top member furthercomprises a first edge, and a second opposite edge; and wherein thefirst and second edges of the top member are inserted into the first andsecond channels formed in the inner surfaces of the first and secondside portions of the base member, thereby slidably attaching the topmember to the base member.
 11. The locking mechanism according to claim1, wherein: the first and second channels formed in the inner surfacesof the first and second side portions of the base portion are parallelto the plane of the base portion of the base member, and are locatednear the top edges of the first and second side portions of the basemember; and the first and second channels terminate prior to thelongitudinal ends of the first and second side portions of the basemember.
 12. The locking mechanism according to claim 1, wherein thesecond projection of the locking member is contained within a wellformed in the top surface of the base portion of the base member whenthe top member is in the unlocked position.
 13. The locking mechanismaccording to claim 1, wherein the locking member is adjacent to the topmember.
 14. The locking mechanism according to claim 1, wherein: theprotrusion of the top member comprises a first surface that is angledrelative to the plane of the top member, and a second surface that isparallel to the plane of the top member and the longitudinal movement ofthe top member; the first projection of the locking member comprises athird surface that is substantially parallel to the second surface ofthe protrusion of the top member; wherein initial longitudinal movementof the top member in the first locking direction causes the firstsurface of the protrusion of the top member to contact the first surfaceof the first projection of the locking mechanism, thereby applying aforce to the first projection of the locking member, wherein the forcehas a vector component directed at the base member; and wherein completelongitudinal movement of the top member in the first locking directioncauses the second surface of the protrusion of the top member to alignwith the third surface of the first projection of the locking member.15. The locking mechanism according to claim 1, wherein: a strap isprovided having a planar shape and a plurality of transverse teethlongitudinally spaced along one major surface of the strap; and thesecond projection of the locking member forms a pawl shaped to allow thesecond projection to engage the transverse teeth of the strap when thestrap is inserted into the longitudinal channel and the locking memberis pivoted into a locked position.
 16. A locking mechanism comprising: abase member having a longitudinal channel for receiving a free end of astrap, the base member comprising a base portion, a first side portionconnected to the base portion, and a second side portion connected tothe base portion, wherein the base portion, first side portion andsecond side portion form the longitudinal channel; a locking membercomprising a first projection extending in a first direction, whereinthe first projection has a first surface and a second opposite surface,and a second projection connected to the first projection and extendingin a second direction; a top member comprising a top portion, and one ormore protrusions formed in the top portion and extending toward thelocking member; means for pivotally attaching the locking member to thebase member so that the locking member is pivotable between a lockedposition and an unlocked position; means for slidably attaching the topmember to the base member so that the top member is slidable between alocked position and an unlocked position; means for inhibiting thewithdrawal of the strap; and means for allowing the withdrawal of thestrap.
 17. The locking mechanism of claim 16, wherein the means forinhibiting the withdrawal of the strap prevents the top member fromsliding from the locked position to the unlocked position when lateralforced is applied to a strap inserted into the longitudinal channel. 18.A system for adjusting an orthotic device, the system comprising: anorthotic device comprising a first brace portion, a bracket portionattached to the first brace portion, the bracket portion comprising afirst projection defining an axis and having a plurality of apertureslongitudinally spaced along a portion of the first projection's length,and a second projection spaced apart from the first projection anddefining an axis that is parallel to the axis of the first bracket, thesecond projection having a plurality of apertures longitudinally spacedalong a portion of the second projection's length, a second braceportion slidably attached to the bracket portion and comprising a bodyportion, a pair of locking members spaced apart from one another, eachlocking member comprising a top portion having an aperture, a first sideportion having a first end attached to the body portion and a secondopposite end attached to the top portion, a second side portion having afirst end attached to the body portion and a second opposite endattached to the top portion, wherein the top portion, first side portionand second side portion form a longitudinal channel configured toreceive one of the first or second projections of the bracket portion,and a locking portion slidably attached to the top portion of thelocking member, the locking portion comprising: a locking portionattached to the top portion of the locking member, the locking portioncomprising: a pin having a diameter smaller than the aperture in the topportion of the locking member, the pin comprising a first end sized tofit within each of the apertures of the projections of the bracketportion, a first projection proximate to the first end of the pin anddefining an axis substantially perpendicular to the longitudinal axis ofthe pin, a second opposite end having a second projection defining anaxis substantially parallel to the first projection, a spring configuredto apply a force to the first projection in a direction toward the planeof the body portion of the second brace portion; and wherein the pinbeing slidable between a first locked position and a second unlockedposition along an axis defined by the longitudinal axis of the pin, andan adjustment tool comprising a body portion having a first end portionand a second end portion that is spaced apart from the first endportion, a first slot foamed in the first end portion, the first slotdefining an axis, a first pair of surfaces adjacent to the first slotand tapered in a direction parallel to the axis of the first slot, asecond slot formed in the second end portion, the second slot definingan axis parallel to the axis of the first slot, and a second pair ofsurfaces adjacent to the second slot and tapered in a direction parallelto the axis of the second slot.
 19. The locking mechanism of claim 18,wherein the first brace portion is a mandibular support and the secondbrace portion is a front sternum plate.
 20. An adjustment toolcomprising: a body portion having a top major surface and a bottom majorsurface; a first end portion comprising a first projection defining anaxis, the first projection comprising a first top surface adjacent tothe body portion, and a second top surface adjacent to the first topsurface and angled relative to the plane of the first top surface, and asecond projection spaced from the first projection and defining an axisparallel to the axis of the first projection, the second projectioncomprising a first top surface adjacent to the body portion, and asecond top surface adjacent to the first top surface and angled relativeto the plane of the first top surface; and a second end portion oppositethe first end portion and comprising a first projection extendinglongitudinally in a first direction and having: a first top surfaceadjacent to and parallel with the top major surface of the body portion,a second top surface adjacent to the first top surface and angledrelative to the plane of the first top surface, and a bottom surfaceadjacent to and parallel with the bottom major surface of the bodyportion and longitudinally coextensive with the second top surface, anda second projection extending generally parallel to the first projectionand having a first top surface adjacent to and parallel with the topmajor surface of the body portion, a second top surface adjacent to thefirst top surface and angled relative to the plane of the first topsurface, and a bottom surface adjacent to and parallel with the bottommajor surface of the body portion and longitudinally coextensive withthe second top surface.